Systems and methods of providing haptic feedback

ABSTRACT

A haptic communication system includes either a switch assembly or a compilation of discretely installed components. The switch assembly and the installed components utilize a haptic actuator to elicit tactile and/or audibly perceptible haptic outputs. The switch assembly and/or a collective haptic communication system includes a processor communicating with the actuator. Computerized instructions cause the processor to receive a message from an external system, identify either an audio or vibrational output signal, and communicate the output signal to the actuator. The audio or vibrational output signal causes the actuator to propagate a respective pressure wave that elicits an audible or inaudible, vibrational response at the output surface of the actuator. The pressure wave causes tactilely and/or audibly perceptible vibration within the individual switch assembly or within an overall installation such as a seat or steering assembly in a vehicle.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Application No. 62/442,406,entitled “Systems and Methods of Providing Haptic Feedback,” filed Jan.4, 2017, the content of which is herein incorporated by reference in itsentirety.

BACKGROUND

Conventional haptic communication systems include eccentric rotatingmass (ERM) devices that vibrate the structure to which the device iscoupled. ERMs are bulky and expensive, which prevents their widespreaduse in steering assemblies and other components of vehicles. Inaddition, ERMs cannot output an audio signal.

Thus, there is a need in the art for a haptic communication system thatprovides sufficient feedback to the operator and that is easilyimplemented into vehicle components.

BRIEF SUMMARY

In a first embodiment, a haptic communication system includes a conelessvoice coil coupled to a steering assembly, a processor in electricalcommunication with the coneless voice coil, a memory, and a vehiclecommunication system that is separate from the haptic communicationsystem. The memory stores instructions for execution by the processor,and the instructions cause the processor to receive a message from thevehicle communication system. In response to receiving the message, theprocessor identifies an audio output signal associated with the messageand communicates the audio output signal to the coneless voice coil. Theaudio output signal causes the coneless voice coil to propagate anaudible pressure wave.

In another embodiment, a haptic communication system includes anactuator having an output surface, and the output surface is coupled toa seat or a steering assembly of a vehicle. The haptic communicationsystem further includes a processor in electrical communication with theactuator, a memory, and a vehicle communication system that is separatefrom the haptic communication system. The memory stores instructions forexecution by the processor, and the instructions cause the processor toreceive a message from the vehicle communication system. The processorthen identifies a vibrational output signal associated with the messageand communicates the vibrational output signal to the actuator. Thevibrational output signal causes the actuator to propagate an inaudiblepressure wave from the output surface against a surface of the seat orsteering assembly. The pressure wave causes tactilely-perceptiblevibration of the seat or steering assembly, respectively.

In yet another embodiment, a switch assembly is configured to be coupledto a steering assembly, wherein the steering assembly has a resonantfrequency. The switch includes a touch plate having a touch surface andan inner surface, and the inner surface is opposite and spaced apartfrom the touch surface. At least one force sensor is disposed adjacentthe inner surface of the touch plate, wherein the at least one forcesensor is configured for receiving a force applied to the touch surface.An actuator has an output surface from which pressure waves arepropagated along an axis of propagation (A-A), and the output surface ofthe actuator is vibrationally coupled to the inner surface of the touchplate. A processor is electrically coupled to a memory, the at least oneforce sensor, the actuator, and a vehicle communication system, thevehicle communication system being separate from the switch assembly.The memory stores instructions for execution by the processor, whereinthe instructions cause the processor to receive a force signal from theat least one force sensor and identify whether a touch event occurredbased on the force signal. In response to identifying the touch event,the processor communicates a first output signal to the actuator, thefirst output signal causing the actuator to propagate a first inaudiblepressure wave having a frequency (f_(I)) within a switch feedbackfrequency range, the switch feedback frequency range being below theresonant frequency (f_(R)) of the steering assembly. The first pressurewave causes a first tactilely-perceptible vibration of the touch platealong the axis of propagation (A-A), wherein the vibration caused by thefirst pressure wave of the first output signal is isolated to the switchassembly.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become apparent from the following description and theaccompanying example implementations shown in the drawings, which arebriefly described below.

FIG. 1 illustrates a perspective view of a switch assembly according toone implementation.

FIG. 2 illustrates an exploded view of part of the switch assembly shownin FIG. 1.

FIG. 3 illustrates a cross sectional view of a partially assembledswitch assembly as taken through the C-C line in FIG. 1.

FIG. 4 illustrates a perspective view of the haptic exciter shown inFIG. 2.

FIG. 5 illustrates a perspective view of the housing shown in FIG. 2.

FIG. 6 illustrates a perspective view of the switch assembly shown inFIG. 2 partially assembled.

FIG. 7 illustrates a perspective view of the second surface of the firstPCB shown in FIG. 2.

FIG. 8 illustrates a perspective view of the second surface of thesecond PCB shown in FIG. 2.

FIG. 9A illustrates a perspective view of the second surface of thelight guide shown in FIG. 2.

FIG. 9B illustrates a perspective view of the first surface of the lightguide shown in FIG. 2.

FIG. 9C illustrates a cross sectional view of the light guide shown inFIG. 2.

FIGS. 10A and 10B illustrate perspective views of the annular frameshown in FIG. 2.

FIG. 11 illustrates a perspective view of the membrane shown in FIG. 2.

FIG. 12 illustrates a plan view of the first surface of the touchoverlay plate shown in FIG. 1.

FIG. 13 illustrates perspective view of a first surface of a light guideaccording to another implementation.

FIG. 14 illustrates a block diagram of an electrical control systemaccording to one implementation.

FIG. 15 illustrates a flow diagram of instructions stored on a memoryfor execution by a processor disposed on the second PCB, according toone implementation.

FIG. 16 illustrates a flow diagram of instructions stored on a memoryfor execution by a processor disposed on the first PCB, according to oneimplementation.

FIG. 17 illustrates a graph of a resistance sensed by the force sensorsand a corresponding force signal associated with each resistance level,according to one implementation.

FIGS. 18A-18D illustrate example touch events and a corresponding hapticresponse to each touch event, according to one implementation.

FIG. 19A illustrates a perspective view of a portion of a switchassembly according to another implementation.

FIG. 19B illustrates a cross sectional view of the portion of the switchassembly shown in FIG. 19A as taken through the D-D line.

FIG. 19C illustrates an exploded view of the portion of the switchassembly shown in FIG. 19A.

FIG. 20A illustrates a perspective view of a portion of a switchassembly according to another implementation.

FIG. 20B illustrates a cross sectional view of the portion of the switchassembly shown in FIG. 20A as taken through the E-E line.

FIG. 20C illustrates an exploded view of the portion of the switchassembly shown in FIG. 20A.

FIG. 20D illustrates a perspective view of a portion of the switchassembly shown in FIG. 20A.

FIG. 21 is a schematic diagram of a vehicle communication system incommunication with the switch assembly according to one implementation.

FIG. 22 is a schematic diagram of a haptic communication system incommunication with a vehicle communication system according to oneimplementation.

FIG. 23 is a cross-sectional view of an actuator assembly coupled to arim portion of a steering wheel assembly, according to oneimplementation. The cross-sectional view is taken through a plane thatbisects the actuator assembly and the rim portion.

FIG. 24 is a perspective view of an exterior surface of a housing of theactuator assembly according to the implementation shown in FIG. 23.

FIG. 25 is a perspective view of an interior surface of the housing anda lower surface of an actuator of the actuator assembly according to theimplementation shown in FIG. 23.

FIG. 26 a perspective view of an inner radial edge and exterior surfaceof the housing of the actuator assembly according to the implementationshown in FIG. 23.

FIG. 27 is a perspective view of a recess defined in a frame of the rimportion of the steering wheel assembly, according to the implementationshown in FIG. 23.

FIG. 28 is a perspective view of the actuator of the actuator assemblydisposed spaced apart from and adjacent the recess shown in FIG. 27.

FIG. 29 is a perspective front view of a steering assembly having fouractuator assemblies coupled thereto, according to one implementation.

DETAILED DESCRIPTION

Various implementations include a switch assembly that includes ahousing and at least two printed circuit boards (PCBs) that are disposedwithin the housing and are axially arranged relative to each other. Oneor more force sensors are disposed on one of the PCBs, and, in someimplementations, the one or more force sensors receive force inputreceived by a touch overlay plate. Signals from the force sensors areprocessed to determine a magnitude, acceleration, and/or location of theforce input, and a haptic feedback response is received by the touchoverlay plate. The haptic feedback response is based on the forcemagnitude, acceleration, and/or location of input, according to someimplementations. Axially arranging the PCBs reduces the footprint of theswitch assembly and allows for the inclusion of more electricalcomponents in the switch assembly, according to some implementations.

Various implementations are described in detail below in accordance withthe figures.

For example, FIGS. 1-12 illustrate a switch assembly according to oneimplementation. The switch assembly 100 includes a housing 102, a firstprinted circuit board (PCB) 110, a second PCB 112, a light guide 142, amembrane 170, an optional touch overlay plate 195, and an annular frame180.

The housing 102 has a first wall 104 and a second wall 106 that define achamber 108. The second wall 106 extends axially from a radial outeredge 105 of the first wall 104, forming a side wall. A distal edge 172of the second wall 106 defines an opening to the chamber 108.Longitudinal axis A-A extends through a center of the chamber 108 andthe first wall 104.

Two or more PCBs are arranged axially adjacent each other within thechamber 108. In particular, a first PCB 110 is disposed within thechamber 108 adjacent the first wall 104, and a second PCB 112 is axiallyadjacent and spaced apart from the first PCB 110 within the chamber 108.A first electrical connector 114 extends from a second surface 116 ofthe first PCB 110, and a second electrical connector 117 extends from afirst surface 118 of the second PCB 112. These electrical connectors114, 117 are axially aligned and coupled together to allow electricalcommunication between the PCBs 110, 112. The first PCB 110 also includesa third electrical connector 120 extending from a first surface 122 ofthe first PCB 110. The third electrical connector 120 is electricallycoupled with a vehicle communication bus, for example. In theimplementation shown, the third electrical connector 120 is axiallyarranged relative to the first electrical connector 114, but theconnectors 120, 114 are not axially aligned. However, in otherimplementations, the third electrical connector 120 is axially alignedwith the first electrical connector 114.

The first wall 104 of the housing includes a first set of one or moreprojections 125 that extend inwardly into the chamber 108 in thedirection of axis A-A. The first surface 122 of the first PCB 110 isdisposed on a distal surface 125 a of the first set of one or moreprojections 125 such that the first surface 122 is spaced apart from thefirst wall 104. The first PCB 110 defines openings 124, and the firstset of projections 125 define openings 126 that are axially aligned withopenings 124. A fastener 127 is engaged through respective pairs ofaligned openings 124, 126 to couple the first PCB 110 to the projections125 and prevent relative movement of the first PCB 110 within thechamber 108. Although three fasteners are shown, more or less fastenersmay be selected. In other implementations, other fastening arrangementsmay be selected. For example, other fastening arrangements include afriction fit within the housing, snaps, clips, rivets, adhesive, orother suitable fastening mechanism.

A second set of projections 128 extend axially inwardly into the chamber108 from the first wall 104 and radially inwardly into the chamber 108(e.g., in a direction perpendicular to and toward the axis A-A) from thesecond wall 106. The second set of projections 128 are spaced apart fromeach other. As shown in FIG. 5, each projection 128 includes a first rib132 and a second rib 134. Each rib 132, 134 includes a proximal edge 133that is coupled to the second wall 106 and a distal edge 135 that isspaced radially inwardly into the chamber 108 from the proximal edge133. The distal edges 135 of ribs 132, 134 intersect and define a boss136. Projections 125 extend between projections 128, but the surface 125a of each projection 125 is spaced apart from a surface 130 of eachprojection 128. In particular, a plane that includes surface 125 a isspaced axially between the first wall 104 and a plane that includessurface 130. The first surface 118 of the second PCB 112 is disposed onthe surfaces 130 of projections 128 such that openings 138 defined inthe second PCB 112 are axially aligned with openings defined by thebosses 136. Fasteners 137 extend through each pair of aligned openings138, 136 to couple the second PCB 112 to the projections 128 and preventrelative movement of the second PCB 112 within the chamber 108. Althoughfour fasteners are shown, more or less fasteners may be selected. Inother implementations, other fastening arrangements may be selected. Forexample, other fastening arrangements include a friction fit within thehousing, snaps, clips, rivets, adhesive, or other suitable fasteningmechanism.

The first PCB 110 has an outer perimeter that is shaped to fit withinthe chamber 108 and between the second set of projections 128, whichallows the first surface 122 of the first PCB 110 to be disposed on thesurface 125 a of projections 125. The second PCB 112 also has an outerperimeter that is shaped to fit within the chamber 108 such that thefirst surface 118 of the second PCB 112 engages the ribs 132, 134 of thesecond set of projections 128.

A plurality of force sensors 140 are disposed on the second surface 123of the second PCB 112 and are spaced apart from each other. The forcesensors 140 are axially aligned with respective first ribs 132 and/orsecond ribs 134. This arrangement allows force to be applied in thez-direction (i.e., along central longitudinal axis A-A) toward the forcesensors 140, and the surfaces 130 of the projections 128 prevent thesecond PCB 112 from bending or flexing where the force sensors 140 arecoupled to the second PCB 112 in response to the force applied, whichprevents the force sensors 140 from being damaged. The surfaces 130 ofthe projections 128 also prevent axial movement of the second PCB 112relative to the first PCB 110 and the housing 102 when force is receivedby the force sensors 140. In one implementation, the force sensors 140comprise micro electro-mechanical sensors (MEMS) that provide an outputsignal that corresponds with an amount of force received by the sensors.For example, the MEMS force sensors are able to detect force with aslittle as 2 microns of displacement.

The light guide 142 is disposed within the chamber 108 and includes afirst surface 144, a second surface 143 that is opposite and spacedapart from the first surface 144, and a side edge 145 that extendsbetween the first surface 144 and the second surface 143. The firstsurface 144 of the light guide 142 faces the force sensors 140 coupledto the second PCB 112. The light guide 142 is a plate made from atransparent or translucent material. For example, the light guide 142may comprise acrylic or a polycarbonate material. At least one lightsource is disposed on the second surface 123 of the second PCB 112. Forexample, in some implementations, the light source includes a lightemitting diode (LED) 146, and the side edge 145 of the light guide 142is disposed radially adjacent the LED 146. Light from the LED 146travels through the side edge 145 of the light guide 142 and exits fromthe second surface 143 of the light guide 142. With this system, asingle light source or multiple light sources are disposed on the sameside, adjacent sides, or opposing sides of the light guide 142, and thelight is directed toward the second surface 143 of the light guide 142.However, in other implementations, the light may enter the light guide142 through the first surface 144 of the light guide 142.

In some implementations, the second surface 143, first surface 144,and/or side edge 145 of the light guide 142 include integrally formedmicro-lenses to direct light through the light guide 142 and out of thesecond surface 143. For example, FIG. 9C illustrates a plurality ofmicro-lenses 147, which include protrusions and/or recessed portions, onthe first surface 144 of the light guide 142. In other or furtherimplementations, one or more light altering films are disposed on one ormore of the light guide surfaces 143, 144 and/or side edge 145 of thelight guide 142.

In the implementation shown in FIG. 9B, the first surface 144 of thelight guide 142 includes a plurality of protrusions 148 that extendaxially from the first surface 144. The protrusions 148 axially alignwith the force sensors 140 on the second PCB 112. The protrusions 148concentrate the force received by the light guide 142 onto the forcesensors 140. In one implementation, the protrusions 148 are integrallyformed with the first surface 144. However, in other implementations,the protrusions 148 may be formed separately and coupled to the firstsurface 144.

In another implementation shown in FIG. 13, the first surface 144′ ofthe light guide 142′ is planar, and a force concentrator that isseparately formed from the light guide 142′ is disposed between eachforce sensor and the first surface 144′ of the light guide 142′. Eachforce concentrator transfers force received by the light guide 142′ tothe respective force sensor below the force concentrator.

The haptic exciter 160 provides haptic feedback to a user. For example,according to one implementation, the haptic exciter 160 is a speaker(e.g., a coneless voice coil assembly), and the haptic output is anaudible or inaudible sound (or pressure) wave that changes the airpressure near an output surface of the speaker by propagating aplurality of pressure waves along an axis of propagation. Thepropagation axis is perpendicular to an output surface 161, and in theimplementation shown, is parallel to central axis A-A, which extendsorthogonally to and through the surfaces 196, 197 of the touch plate195. For example, the propagation axis may be co-axial with axis A-A insome implementations. In the implementation shown in FIGS. 1-12, theoutput surface 161 of the haptic exciter 160 is coupled directly to thefirst surface 144 of the light guide 142. Thus, at least a portion ofthe pressure waves propagated from the output surface 161 are directedtoward and are captured by the first surface 144 of the light guide 142,which causes vibration, or oscillation, of the light guide 142 in thez-direction. In this implementation, the first surface 144 of the lightguide 142 serves as the reaction surface for the exciter 160. Thevibration of the light guide 142 is transferred to the membrane 160 andto the touch plate 195. Thus, the haptic exciter 160 is vibrationallycoupled to the inner surface 196 of the touch plate 195 because pressurewaves originating from the haptic exciter 160 induce a vibratoryresponse on the touch plate 195. In some implementations, the hapticexciter 160 is coupled to the first surface 144 of the light guide 142using an adhesive 162. However, in other implementations, other suitablefastening mechanisms may be used. And, in other implementations, theoutput surface 161 of the haptic exciter 160 is disposed axiallyadjacent and spaced apart from the first surface 144 of the light guide142. In addition, in some implementations, the haptic exciter 160 isdisposed adjacent a central portion of the first surface 144 of thelight guide 142.

As shown in FIG. 4, the haptic exciter 160 includes a flexible cableconnector 164 that has a first end 165 that is coupled to a first end166 of the haptic exciter 160 and a second end 167 that is coupled tothe first surface 118 of the second PCB 112. The flexible cableconnector 164 minimizes or eliminates transmission of the vibration fromhaptic exciter 160 to the second PCB 112 while allowing the hapticexciter 160 to be electrically coupled to the second PCB 112. In onenon-limiting example, the flexible cable connector may be a zeroinsertion force (ZIF)-type connector. In alternative implementations,the haptic exciter 160 is coupled to the second PCB 112 with wires thatare coupled to each via soldering or other suitable coupling mechanism.

In addition, the second PCB 112 defines an opening 163 through which theoutput surface 161 of the haptic exciter 160 extends for coupling theoutput surface 161 to the first surface 144 of the light guide 142. Thisarrangement allows the height in the direction of axis A-A of the switchassembly 100 to be reduced, increases the energy received by the touchoverlay 195 from the haptic exciter 160, and reduces the vibrationalenergy transferred to the second PCB 112. However, in otherimplementations, the second PCB 112 may not define opening 163, and thehaptic exciter 160 may be axially spaced apart from the second surface123 of the second PCB 112 and disposed between the first surface 144 ofthe light guide 142 and the second surface 123 of the second PCB 112. Byspacing the haptic exciter 160 apart from the second PCB 112, thevibrational energy from the haptic exciter 160 is isolated from thesecond PCB 112, which allows more of the energy to be received by thelight guide 142.

The flexible membrane 170 extends over the chamber 108. A first surface171 of the flexible membrane 170 faces the second surface 143 of thelight guide 142, and at least a portion of these surfaces 171, 143 arecoupled together (e.g., by adhesion). A plurality of posts 173 extendaxially from the distal edge 172 of the second wall 106 of the housing102 and are circumferentially spaced apart from each other. The flexiblemembrane 170 defines a plurality of post openings 174 adjacent aradially outer edge 175 of the membrane 170. The posts 173 are engagedthrough respective post openings 174 of the membrane 170 to preventmovement of the membrane 170 in the x-y plane (i.e., plane perpendicularto the central axis A-A). In some implementations, the surfaces 171, 143are coupled together prior to the posts 173 being engaged through theopenings 174. By limiting the movement of the membrane 170 to thez-direction, the membrane 170 is able to transfer the vibration from thelight guide 142 more efficiently, and the membrane 170 can prevent an x-or y-component of force incident on the switch assembly 100 from beingtransferred to the force sensors 140, which prevents damage to the forcesensors 140 due to shear forces.

The membrane 170 is formed of a flexible material that is capable ofresonating in the z-direction. For example, the membrane 170 may be madeof a polymeric material (e.g., polyester, polycarbonate), a thin metalsheet, or other suitable flexible material. In addition, the stiffnessof the material for the membrane 170 may be selected based on the amountof resonance desired and in consideration of the load to be incident onthe membrane 170.

The touch overlay plate 195 has a first surface 196 and a second surface197. At least a central portion 201 of the first surface 196 of thetouch overlay plate 195 is coupled to a second surface 198 of membrane170, and the second surface 197 of the touch overlay plate 195 faces inan opposite axial direction from the first surface 196 and receivesforce input from the user. For example, in one implementation, thesecond surface 198 of the membrane 170 and the central portion 201 ofthe first surface 196 of the touch overlay plate 195 are adheredtogether.

In some implementations, at least a portion of the second surface 197 ofthe touch overlay plate 195 is textured differently than the portion ofthe vehicle adjacent to the switch assembly 100 to allow the user toidentify where the touch overlay plate 195 is in the vehicle withouthaving to look for it. And, in some implementations, as shown in FIG. 3,the second surface 197 includes a non-planar surface. For example, thecontour of the non-planar surface may be customized based on variousapplications of the assembly and/or to facilitate the user locating thesecond surface 197 without having to look for it.

In some implementations, icons are disposed on the touch overlay plate195, and light exiting the second surface 143 of the light guide 142passes through the membrane 170 and the icons on the touch overlay plate195 to illuminate the icons. For example, by providing icons on a sheetthat is adhesively coupled to the touch overlay plate 195, the icons areeasily customizable for each vehicle manufacturer, and the switchassembly 100 is manufactured efficiently.

In some implementations, the flexible membrane 170 oscillates in thez-direction in response to receiving vibrational energy from the hapticexciter 160 via the light guide 142, and this oscillation is transferredto the touch overlay plate 195 to provide the haptic feedback to theuser. Furthermore, the haptic response of the switch assembly 100 istunable by selecting a light guide 142, membrane 170, and touch overlayplate 195 that together have a certain stiffness.

In addition, to isolate the vibration of the light guide 142 and touchoverlay plate 195 from the housing 102 and PCBs 110, 112 and to ensurethat the light guide 142 and touch overlay plate 195 do not rotate aboutthe central axis A-A, an interlocking mechanism is employed to couplethe light guide 142 and the touch overlay plate 195, according to someimplementations. For example, as shown in FIGS. 3, 6, 9A, 11, and 12,the second surface 143 of the light guide 142 defines a second set ofprotrusions 157 that extend axially away from the second surface 143.The second set of protrusions 157 includes two or more protrusions, andthe protrusions 157 are spaced apart from each other. The protrusions157 are disposed radially inward of and adjacent the side edge 145 ofthe light guide 142. The flexible membrane 170 defines openings 158through which the protrusions 157 extend. And, the first surface 196 ofthe touch overlay plate 195 defines recessed portions 159 that extendaxially into the first surface 196. Distal ends of the protrusions 157extend and are seated within the recessed portion 159. In theimplementation shown in FIGS. 9A and 12, there is are four recessedportions 159 defined in the touch overlay plate 195 and threeprotrusions 157 extending from the second surface 143 of the light guide142. Having one or more additional recessed portions 159 allows parts tobe standardized such that they can be used in different areas of thevehicle (e.g., left side or right side). However, in otherimplementations, the interlocking mechanism may include one or moreprotrusions and recessed portions.

In some implementations, a portion or all of the touch overlay plate 195is comprised of a transparent or translucent material and allows lightto pass through the touch overlay plate 195. For example, the touchoverlay plate 195 may comprise a piece of clear, contoured glass. Othertransparent or translucent materials can be used, including othercrystal materials or plastics like polycarbonate, for example. Thecontoured nature of one side, the second side 197, of the touch overlayplate 195 allows the user to move around their finger to find the rightbutton location without having to initiate the switch past the forcethreshold.

The annular frame 180 includes an annular wall 181 and a side wall 182that extends axially from adjacent an outer radial edge 183 of theannular wall 181. The annular wall 181 includes an inner radial edge 184that defines an opening 185 having a central axis B-B. The annular wall181 also defines one or more post openings 186 between the inner radialedge 184 and the outer radial edge 183. The annular frame 180 is coupledto the second wall 106 of the housing 102. When coupled together, aninner surface 187 of the side wall 182 is disposed adjacent an outersurface 107 of the second wall 106. A portion of the membrane 170adjacent the outer radial edge 175 of the membrane 170 is disposedbetween the annular wall 181 and the distal edge 172 of the second wall106. Posts 173 are engaged through openings 174 defined in the membrane170 and within respective post openings 186 of annular wall 181 toprevent movement in the x-y plane of the annular frame 180 relative tothe housing 102. When coupled, the axis B-B of the annular frame 180 iscoaxial with axis A-A of the housing 102. In the implementation shown,at least a portion of the outer radial edge 175 of the membrane 170folds over the distal edge 172 of the second wall 106 and is disposedbetween the inner surface 187 of side wall 182 of the annular frame 180and the outer surface 107 of the second wall 106. Furthermore,protrusions 157 are disposed radially inward of the inner radial edge184 of the annular wall 181 when the annular frame 180 is coupled to thehousing 102.

Fastener openings 188 are defined in the annular wall 181, and fasteneropenings 177 are defined by the second wall 106 of the housing 102.Fasteners 189 are engaged through aligned pairs of openings 188, 177 tocouple the annular frame 180 to the housing 102. For example, in theimplementation shown in FIGS. 1-12, the annular wall 181 includes radialextensions 181 a that extend radially outwardly from the wall 181 anddefine the fastener openings 188. And, radial extensions 106 a extendradially outwardly from the wall 106 and define fastener openings 177.However, in other implementations, the annular frame 180 is coupled tothe housing 102 using other fastening arrangements. For example, in someimplementations, the annular frame 180 is coupled to the housing 102 viafasteners extending through the side wall 182 of the annular frame 180and the outer surface 107 of the second wall 106 of the housing 102. Inother implementations, the annular frame 180 is coupled to the housing102 using a friction fit, snaps, clips, rivets, adhesive, or othersuitable fastening mechanism.

In certain implementations, one or more springs are disposed between theannular wall 181 of the annular frame 180 and the light guide 142 tourge the light guide 142 toward the second surface 123 of the second PCB112. By disposing one or more springs between the annular wall 181,which is fixedly coupled to the housing 102, and the light guide 142,the one or more springs pre-load the force sensors 140. For example, theone or more springs may pre-load the force sensors to between 1 and 5 N.In one non-limiting example, the one or more springs pre-load the forcesensors to 2.8 N. For example, in the implementation shown in FIGS.1-12, the springs include coil springs 190 that extend between a firstsurface 205 of the annular wall 181 and the second surface 143 of thelight guide 142. Axial depressions 206 are defined in a recessed portion207 defined by the second surface 143 of the light guide 142 and theside edge 145 of the light guide 142. The recessed portions 207 have asurface that is axially spaced apart from the second surface 143 of thelight guide 142 in a direction toward the first surface 144 of the lightguide 142. Inward radial extensions 204 extend radially inwardly fromthe inner radial edge 184 of the annular wall 181. The inward radialextensions 204 also define axial depressions 306 according to someimplementations. The axial depressions 306 defined by the inward radialextensions 204 are axially aligned with the axial depressions 206defined by the light guide 142, and ends of each spring 190 seats in therespective axially aligned axial depression 306 of the inward radialextension 204 and the axial depression 206 of the light guide 142 toprevent movement of the coil spring 190 in the x-y plane. In addition,the membrane 170 defines spring recesses 178 that extend radiallyinwardly from the outer radial edge 175 of the membrane 170, and thesprings 190 extend through the recesses 178 and are spaced apart fromthe outer radial edge 175 of the membrane 170 so as not to interferewith the oscillation of the membrane 170.

In the implementation shown in FIGS. 19A-19C, the springs are leafsprings 290. The leaf springs 290 include a central portion 291 and legportions 292 a, 292 b. Leg portions 292 a, 292 b extendcircumferentially from and radially inwardly from the central portion291. The second surface 243 of the light guide 242 includes a pluralityof posts 293 that extend axially away from the second surface 243, andthe membrane 270 defines openings 279 through which the posts 293extend. The central portion 291 of each leaf spring 290 is coupled tothe first surface 255 of the annular wall 281 of the annular frame 280,and the leg portions 292 a, 292 b engage distal ends 294 of posts 293.When assembled, a plane that includes the first surface 255 of theannular wall 281 to which the central portion 291 of the leaf spring 290is coupled is axially between a plane that includes the distal ends 294of the posts 293 and a plane that includes the second surface 243 of thelight guide 242. Thus, the leg portions 292 a, 292 b of the leaf spring290 are biased toward the light guide 242 and urge the first surface 244of the light guide 242 toward the second PCB 112. It is to beappreciated that the posts 293 may be separate from the light guide 242,or they can be integrally formed with the light guide 242.

FIG. 19B also shows a second set of protrusions 257, which are similarto the second set of protrusions 157 shown in FIGS. 3, 6, 9A, 11, and12, that extend axially away from the second surface 243 of the lightguide 242. The second set of protrusions 257 includes three protrusions,and the protrusions 257 are spaced apart from each other. Theprotrusions 257 are disposed radially inward of and adjacent the sideedge 245 of the light guide 242. Like the protrusions 157 describedabove, the protrusions 257 extend through openings in the membrane andinto recessed portions defined by the first surface of the touchoverlay.

FIGS. 20A-20D illustrate leaf spring 390 according to anotherimplementation. In this implementation, the leaf spring 390 includes acentral portion 391 and leg portions 392 a, 392 b that extendcircumferentially from and radially inwardly from the central portion391. Each leg portion 392 a, 392 b also includes an arcuate portion 393having an apex 394 that is within a plane that is spaced apart from aplane that includes the central portion 391. The central portion 391 iscoupled to the first surface 355 of an annular wall 381, and the apex394 of each arcuate portion 393 abuts the second surface 343 of thelight guide 342. The arcuate portion 393 maintains a minimum axialspacing between the second surface 343 of the light guide 342 and thefirst surface 355 of the annular wall 381.

At least a portion of the leaf spring 390 is coupled to the annularframe 380. The inner radial edge 384 of the annular wall 381 includesone or more resilient tabs 375 that extend axially in a first direction(i.e., in a direction away from and orthogonal to the first surface 355of the annular wall 381) from the inner radial edge 384. Each resilienttabs 375 has a shoulder 376 that extends radially outwardly from the tab375 toward the first surface 355 of the annular wall 381. Each shoulder376 is axially spaced apart from the first surface 355 of the annularwall 381. The side wall 382 of the annular frame 380 also includes oneor more tabs 378 that extend radially inwardly from an inner surface 383of the side wall 382. The one or more tabs 378 are axially spaced apartfrom the first surface 355 of the annular wall 381. The first surface355 of the annular wall 381 includes one or more protrusions 379 thatextend axially in the first direction from the first surface 355. Aradially outer edge 331 of the central portion 391 of the leaf spring390 is urged axially between tabs 378 and the first surface 355 of theannular wall 381, and a radially inner edge 332 of the central portion391 is urged against the resilient tabs 375, which causes the resilienttabs 375 to bend radially inwardly as the leaf spring 390 passes by theshoulders 376 and is disposed between the shoulders 376 and the firstsurface 355 of the annular wall 381. Also, a concave surface of eacharcuate portion 393 is positioned to face axially toward the firstsurface 355 of the annular wall 381 such that the apex 394 faces awayfrom the first surface 355. The leaf spring 390 defines one or moreopenings 377 that align with the one or more protrusions 376, and theprotrusions 376 extend through the openings 377 when the edges 331, 332are disposed between the tabs 375, 378 and the first surface 355 of theannular wall 381. The tabs 375, 378 hold the leaf spring 390 axially andradially adjacent the annular frame 380, and the protrusions 376 engagedthrough the openings 377 prevent the leaf spring 390 fromcircumferential movement relative to the annular frame 380.

In other implementations, the leaf spring 290, 390 is over-molded with aportion of the annular frame 280, 380 over the central portion 291, 391thereof. And, in some implementations, the spring 290, 390 may beadhered to, snapped to, or otherwise fastened to the annular frame 280,390.

In addition, according to various implementations, the leaf spring 290,390 may comprise a spring steel plate.

The central portion 201 of the touch overlay plate 195 is disposedwithin the opening 185 defined by the inner radial edge 184 of theannular wall 181 and is coupled to the membrane 170, as described above.As shown in FIG. 12, the first surface 196 of the touch overlay plate195 defines a recessed portion 199 adjacent an outer radial edge 200 ofthe touch overlay plate 195. The recessed portion 199 and an outerradial edge 202 of the central portion 201 of the first surface 196further define a plurality of depressions 203 (or grooves) that extendaxially from the first surface 196 of the central portion 201 to theannular recessed portion 199 and radially inwardly from the outer radialedge 202. To prevent the touch overlay plate 195 from contacting theannular frame 180, the depressions 203 are spaced radially inwardly ofthe radial extensions 204 of the annular wall 181 of the annular frame180. In addition, the distance T_(T) between the surface of the annularrecessed portion 199 and the surface of the central portion 201 isgreater than a thickness T_(A) (as measured in the z- or axialdirection) of the annular wall 181. And, a diameter (or width W_(T)) ofthe second surface 197 of the touch overlay plate 195 is greater than adiameter (or width W_(A)) of the annular wall 181 such that the touchoverlay plate 195 hides the annular wall 181 when the assembly 100 isviewed from the second surface 197 of the touch overlay plate 195.

In some implementations, such as those described above, the distal edge172 of the second wall 106 of the housing 102, the annular frame 180,the light guide 142, and the outer radial edge 200 of the touch overlayplate 195 are generally circular. However, in other implementations,these portions of the switch assembly may have a non-circular shape,such as triangular, rectangular, or other suitable polygonal shape. Inother implementations, the switch assembly includes just one PCB onwhich the force sensors are disposed. In such implementations, thecircuitry required to operate the switch fits on the one PCB.

In addition, in other implementations, the switch assembly may includejust one PCB and one force sensor for applications that require outputfrom one force sensor (output that is not position specific).

455 In some implementations, the switch assemblies described above aremountable within a vehicle. For example, the switch assemblies aremountable to a steering wheel, such as to the bevel or hub of thesteering wheel, for use in controlling various vehicle systems. In otherexamples, the switch assemblies are mountable to a vehicle door, gearshifter, dashboard, or any portion of the vehicle where input can beprovided and used to control one or more vehicle systems.

For example, in some implementations, such as those described above, thehousing is coupled to a trim piece in the vehicle instead of a frame orsupport portion of the vehicle, which isolates the vibration from thehaptic exciter from other portions of the vehicle. This arrangement alsoallows the gap between edges of the trim piece and the outer edge of theassembly to be minimized because the trim piece can move with theassembly. To couple the housing to the trim piece (or other portion ofthe vehicle), bosses 208 that extend radially outwardly from the outersurface of second wall are aligned with openings defined adjacent theportion of the vehicle to which the switch assembly is being coupled. Afastener is engaged through the aligned openings to secure the assemblyto the vehicle.

FIG. 14 illustrates a block diagram of the electrical control system500, according to one implementation. The electrical control system 500may include a computing unit 506, a system clock 508, and communicationhardware 512. In its most basic form, the computing unit 506 includes aprocessor 522 and a system memory 523 disposed on the second PCB 112.The processor 522 may be standard programmable processors that performarithmetic and logic operations necessary for operation of theelectrical control system 500. The processor 522 may be configured toexecute program code encoded in tangible, computer-readable media. Forexample, the processor 522 may execute program code stored in the systemmemory 523, which may be volatile or non-volatile memory. The memory523, which can be embodied within non-transitory computer readablemedia, stores instructions for execution by the processor 522. Thesystem memory 523 is only one example of tangible, computer-readablemedia. In one aspect, the computing unit 506 can be considered anintegrated device such as firmware. Other examples of tangible,computer-readable media include floppy disks, CD-ROMs, DVDs, harddrives, flash memory, or any other machine-readable storage media,wherein when the program code is loaded into and executed by a machine,such as the processors 522, 532, the machine becomes an apparatus forpracticing the disclosed subject matter.

In addition, the processor 522 is in electrical communication with theforce sensors 140. The processor 522 may also be in electricalcommunication with peripheral vehicle systems that are availablethroughout a vehicle to ensure proper mechanical operation or to createenhanced driving experiences. The peripheral vehicle systems gather andutilize a plurality of operational input signals received fromenvironmental sensors positioned throughout the vehicle. In someimplementations, the system 500 further includes a transceiver that isin electrical communication with the processor 522, one or more of theperipheral vehicle systems, and the environmental sensors installedthroughout the vehicle. In other non-limiting implementations, thesystem 500 further includes at least one power amplifier 530 that is inelectrical communication with the processor 522 and/or at least onerespective haptic exciter 160. The amplifier 530 may be configured todynamically adjust environmental data inputs received from theperipheral vehicle systems and directed to a haptic exciter 160, or theprocessor 522 may utilize the amplifier 530 for dynamic control of asystem of haptic exciters 160. Dynamically controlling at least onehaptic exciter 160 with a signal subject to varying degrees ofamplification allows for the at least one haptic exciter 160 to providea driver with feedback that is tailored for conditions that change overtime. For example, and without limiting the invention, the processor 522may instruct the amplifier 530 to adjust the magnitude of a series ofactuator input signals or portions thereof. With the processor 522controlling not only the switching and selection of at least one hapticexciter 160, the processor 522 may also instruct the system 500 toactuate at least one haptic exciter 160 to account for response times ofthe system 500, adjust the tactile responses according to environmentalconditions about the vehicle, and provide a driver with sequences ofhaptic outputs and/or audio outputs having controlled combinations ofmagnitudes, positions on a steering wheel, and duration.

However, in other implementations, the system 500 includes two or moreprocessors and/or memories, and the processors and/or memories may bedisposed on the first and/or second PCBs. And, in other implementations,the assembly includes one or more PCBs on which one or more forcesensors, one or more memories, and one or more processors are disposed.

Aspects of the present invention are described above with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems) and computer program products according to implementations ofthe invention. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, can be implemented bycomputer program instructions. These computer program instructions maybe provided to a processor of a general purpose computer, specialpurpose computer, or other programmable data processing apparatus toproduce a machine, such that the instructions, which execute via theprocessor of the computer or other programmable data processingapparatus, create means for implementing the functions/acts specified inthe flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a computerreadable medium that can direct a computer, other programmable dataprocessing apparatus, or other devices to function in a particularmanner, such that the instructions stored in the computer readablemedium produce an article of manufacture including instructions whichimplement the function/act specified in the flowchart and/or blockdiagram block or blocks.

The computer program instructions may also be loaded onto a computer,other programmable data processing apparatus, or other devices to causea series of operational steps to be performed on the computer, otherprogrammable apparatus or other devices to produce a computerimplemented process such that the instructions which execute on thecomputer or other programmable apparatus provide processes forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks.

FIG. 15 illustrates a flow diagram of instructions stored in the firstmemory 523 for execution by the first processor 522 according to oneimplementation. The instructions cause the first processor 522 to: (1)receive a signal from each of the one or more force sensors 140, thesignal being associated with a force received by each of the forcesensors 140, as shown in step 1102, (2) determine a force magnitudeand/or x,y location associated with the received force signals, as shownin step 1104, and (3) communicate the force magnitude and/or x,ylocation to the second processor 532 disposed on the first PCB 110, asshown in step 1106. Having the force sensors 140 in close proximity tothe first processor that initially processes the signals from the forcesensors 140 reduces the likelihood of noise in the signals.

FIG. 16 illustrates a flow diagram of instructions stored in the secondmemory 533 for execution by the second processor 532. The instructionsstored in the second memory 533 cause the second processor 532 to: (1)receive the force magnitude and/or x,y location from the first processor522, as shown in step 1202, (2) identify a haptic feedback responseassociated with the force magnitude and or x,y location as shown in step1204, (3) communicate the haptic feedback response to a haptic exciter160, as shown in step 1206, and (4) communicate the x,y location and/orthe force magnitude to another vehicle system, as shown in step 1208.The switch assembly 100 according to one implementation may beconfigured for controlling up to 32 functions.

The force sensors 140 each receive a portion of the force applied to thetouch overlay 195, and the force received by each sensor 140 isprocessed by the first processor 522 to determine a position andmagnitude of the force applied. The position of the force is determinedby the portion of the force received by each force sensor 140 and theirknown location relative to each other. For example, in theimplementation shown in FIG. 17, the force received by each sensor 140(shown on the x-axis) is associated with a resistance (shown on they-axis). The position of the applied force is measured in either onedimension (e.g., the x- or y-dimension) or two dimensions (e.g., the x-and y-directions or plane), and the magnitude of the force is measuredin the z-direction. In the implementation shown in FIGS. 1-12, which hasfour force sensors 140, the position of the force is determined byquad-angulation of the force signals received from each sensor 140. Infurther or alternative implementations, the position of the force isdetermined by tri-angulation using three force sensors. For example, ifone of the four force sensors 140 fails during operation, the locationis determined by tri-angulation using the force signal received from theremaining three sensors 140.

The switch assembly 100 also senses the time that a force is applied ata particular location. For example, the memory 523 may store processingparameters, such as a range of force over time values that indicate aninput signal has been received. Input received outside of the range maybe ignored by the system as unintentional contact with the switchassembly 100. For example, the upper limit of the input range may be 10Nof force applied for 20 seconds or less. Furthermore, the switchassembly 100 may also set a force threshold for locking an input area(e.g., 2.5 N) around a location of force input and a second, higherthreshold for a force received within the input area for enabling thesystem 100 (e.g., 3 N). Additional description of force thresholds andvirtual input areas are provided in U.S. Patent Application PublicationNos. 2015/0097791 and 2015/0097795, both published Apr. 9, 2015, whichare included in the Appendix to this application.

In response to the magnitude, location, and/or duration of the appliedforce meeting the input parameters, the switch assembly 100 generates ahaptic and/or audible feedback signal responsive to the detected force.For example, the haptic and/or audible feedback signal may beproportional to the force received. As shown in FIGS. 18A-D, each touchevent (e.g., touch-down shown in FIG. 18A, lift-off shown in FIG. 18B,end of list shown in FIG. 18C, and hold-down shown in FIG. 18D) isinitiated by a different user interaction (e.g., different force valueand/or duration of the touch) and, accordingly, can trigger differenthaptic and/or audible output feedbacks provided to the user. Examplehaptic and/or audible feedback signal responses are described in U.S.Patent Application Publication Nos. 2015/0097794 and 2015/0097793, bothpublished Apr. 9, 2015, which are herein incorporated by reference intheir entireties.

The drawings illustrate the switch assembly as viewed in an uprightorientation in which the central longitudinal axis A-A is verticallyoriented. However, the orientation shown in the drawings should notlimit how the switch assembly may be oriented within the vehicle. Forexample, in various implementations, the switch assembly is disposed inthe vehicle such that the central longitudinal axis A-A is horizontal orhas a horizontal component relative to the ground.

In further implementations, the haptic exciter of the switch assembly100 is used to provide haptic feedback to a user of the switch assembly100 and to vibrate adjacent portions of the steering assembly or theentire steering assembly in response to receiving a communication from avehicle communication system. For example, in one such implementationshown in FIG. 21, the memory 523 stores instructions for execution bythe processor 522, and the instructions cause the processor to receive aforce signal 2140 from the at least one force sensor 140 and identifywhether a touch event occurred at the touch surface 197 of the touchplate 195, based on the force signal 2140. In response to identifyingthe touch event, the processor 522 communicates a first output signal2110 to the haptic exciter (or actuator) 160, and the first outputsignal 2110 causes the haptic exciter 160 to propagate a first inaudiblepressure wave 2161A having a frequency within a switch feedbackfrequency range. The first pressure wave 2161A causes a firsttactilely-perceptible vibration on the touch surface 197 along the axisof propagation. The switch feedback frequency range includes thosefrequencies that assist in isolating the haptic response perceived bythe user to the switch assembly 100 without causing a correspondinghaptic response in an associated installation, such as the steeringassembly or other portion of the vehicle to which the switch assembly100 is coupled. For example, the switch feedback frequency rangeincludes a series of frequencies below a resonant frequency of thesteering assembly 50 that help to isolate the vibration from the firstinaudible pressure wave 2161A to the touch surface 197. By triggering afirst output signal 2110 from the processor to stimulate an inaudiblepressure wave having frequency from the actuator, the switch assemblyaccommodates a haptic response that is substantially contained withinthe structure of the switch assembly 100.

And, in some implementations, in response to receiving a message 2108from the vehicle communication system 2100, the instructions furthercause the processor 522 to communicate a second output signal 2112 tothe haptic exciter 160. The second output signal 2112 causes the hapticexciter 160 to propagate a second inaudible pressure wave 2161B that isclose to or at the resonant frequency of the steering assembly 50. Thesecond pressure wave 2161B causes a second tactilely-perceptiblevibration of the steering assembly. For example, the frequency of thesecond inaudible pressure wave 2161B may be selected from a range offrequencies that includes the resonant frequency of the steering wheel.The minimum frequency in the range is the minimum frequency required tocause tactilely perceptible vibration of a rim portion of the steeringassembly, and the maximum frequency is the maximum frequency that doesnot cause damaging vibrational movement to the steering assembly.

Example messages 2108 may include communications from a speedometer,accelerometer, suspension sensors, hand detection system, horn system,or any other vehicle system that may need to communicate a vehicleoperation status, warning, or other information to a vehicle occupant.In addition, one example message may include a warning that the car isout of its lane, and the vibration caused by the second inaudiblepressure wave 2161B simulates driving over rumble strips defined onroadways.

To coordinate data input and output from the switch assembly 100, theprocessor 522 is electrically coupled to the memory 523, the forcesensors 140, the haptic exciter 160, and the vehicle communicationsystem 2100. As shown in FIG. 21, the vehicle communication system 2100is separate from the switch assembly 100. In addition, the vehiclecommunication system 2100 may be in electrical communication with avehicle safety system 2105 and/or a vehicle operation system 2106 andcan communicate messages from these systems 2105, 2106 to the processor522. Alternatively, the vehicle safety system 2105 and/or the vehicleoperation system 2106 may be electrically coupled to the processor 522separately from the vehicle communication system 2100.

The haptic exciter 160 may include a speaker. For example, the speakermay include a standard voice coil assembly with the cone removed. Thecomputerized instructions stored in the memory 523 further cause theprocessor 522 to select an audible pressure wave from one or morememory-stored audible pressure waves and communicate a third outputsignal 2114 to the speaker. The third output signal 2114 from theprocessor 522 causes the speaker to propagate the selected audiblepressure wave.

In some implementations, the instructions stored in the memory 523 causethe processor to communicate to the speaker the output signal 2114 andthe vibrational output signal 2112 in sequence. The audio output signal2114 may be communicated before the vibrational output signal, or viceversa. Both the output signal 2114 and the vibrational output signal2112 may be subject to instructions from the processor 522 and theamplifier 530, described above as initiating combinations and sequencesof outputs of haptic and audio effects from at least one haptic exciter160. The system 500 is, therefore, a dynamically tunable arrangement ofhaptic exciters 160 controlled by at least one processor 522 inconjunction with appropriate switching and amplification circuits. And,the processor 522 may delay the communication of each signal 2114, 2112by a predetermined time period. For example, in one implementation, thedelay may be 25 milliseconds or less. In other implementations, thedelay can be selected based on the haptic effect desired for the user.

To increase efficiencies and to control the haptic sensationsexperienced by a user, some implementations of the switch assembly 100incorporate computerized logic to account for ambient vibration. In suchimplementations, the memory 523 stores additional computerizedinstructions that cause the processor 522 to receive an ambientvibration signal associated with ambient vibration of the steeringassembly, identify a pressure wave offset associated with the ambientvibration, and modify the second output signal 2112 based on theidentified pressure wave offset. This modification to the second outputsignal 2112 changes at least one characteristic of the second pressurewave propagated from the haptic exciter 160. Example pressure waveoffsets includes frequency offsets, amplitude offsets, and/or durationoffsets. In addition, the frequency with which each discrete pressurewave is propagated may be modified based on the ambient vibrationsignal.

In some implementations, the ambient vibration relevant to the pressurewave offset may be determined using the force signals 2140 from theforce sensors 140. The ambient vibration signal is determined by theprocessor 522 based on an average magnitude and frequency of each of theforce signals 2140 generated by the force sensors 140. To avoid falsereadings and noise issues, the processor 522 determines whether anaverage magnitude of the force signals 2140 exceeds a threshold, and theprocessor 522 identifies the pressure wave offset in response todetermining that the average magnitude exceeds that threshold. In otherimplementations, the ambient vibration signal may be determined usingone or more signals received from an accelerometer that is coupled tothe steering assembly and is in electrical communication with theprocessor 522.

In further or additional implementations, the processor 522 may identifya pressure wave offset associated with the vehicle speed, a warningmessage received from the vehicle safety system 2105, and/or anoperation message received from the vehicle operation system 2106 andmodify the second output signal 2112 based on the identified pressurewave offset. In addition, the frequency with which each discretepressure wave is propagated may be modified based on the speed, warningmessage, and/or operation message.

In addition, in some implementations, two or more switch assemblies 100may be used to provide haptic communication to the user. As describedbelow in relation to FIG. 22, the haptic output of the switch assemblies100 may be coordinated by one or more processors to provide an overallhaptic response for the user, based on the message received by the oneor more processors.

Although the ability to provide various levels of haptic outputs isdescribed above in relation to the switch assembly 100 shown in FIGS.1-20, other switch assemblies than the switch assembly 100 describedabove may be used to receive and provide haptic feedback for touch inputand to vibrate at least a portion of the steering assembly. Exampleswitch assemblies include a touch plate that includes a touch surfaceand an inner surface that is opposite and spaced apart from the touchsurface, at least one force sensor disposed adjacent the inner surfaceof the touch plate and that receives a force applied to the touchsurface, and an actuator having an output surface from which pressurewaves are propagated along an axis of propagation. The output surface ofthe actuator is vibrationally coupled to the touch plate.

Other implementations include a haptic communication system 2500 thatincludes at least one actuator 460 coupled to a portion of the vehiclethat is likely to be in physical contact with an occupant or that cantransfer vibration to a portion of the vehicle likely to be in physicalcontact with the occupant. For example, the actuator 460 may be coupledto the steering assembly 50 separately from a switch assembly, such asswitch assembly 100 or those described above, or within a seat 60. Theactuator 460 has an output surface, and the output surface is coupled(either physically or vibrationally) to the steering assembly 50 or theseat 60. The system 2500 also includes a processor 2522 that is inelectrical communication with the actuator 460, a memory 2523, and thevehicle communication system 3100, which is separate from the hapticcommunication system 2500. The vehicle communication system 3100 is inelectrical communication with vehicle safety system 3105 and vehicleoperation system 3106, and vehicle communication system 3100communicates messages from systems 3105, 3106 to the processor 2522. Inalternative implementations, systems 3105 and/or 3106 are electricallycoupled directly with the processor 2522. The memory 2523 is similar tomemory 523 described above, and the processor 2522 is similar to theprocessor 522 described above.

In example installations in which the actuator 460 is coupled(physically and/or vibrationally) to the steering assembly 50, theactuator 460 is spaced apart from the steering wheel frame. In someimplementations, the output surface of the actuator 460 is physicallyand vibrationally coupled to a non-frame surface of the steeringassembly 50, and the non-frame surface amplifies and propagates theinaudible and/or audible pressure wave output from the output surface ofthe actuator 460, similar to a cone of a standard voice coil assembly.The surface to which the output surface is coupled acts as the coneportion of a standard voice coil assembly.

For example, the actuator 460 may be disposed adjacent a spoke portion62A, 62B of the steering wheel frame but is spaced apart from the frame.For example, the actuator 460 may be directly coupled to the outer trimof the spoke portion 62A, 62B. In some embodiments, the actuator 460 maybe disposed between a frame of the hub portion and an outer trim of thehub portion. For example, the actuator 460 may be coupled to an innersurface of a cover of an air bag module that is coupled to the hubportion of the frame of the steering assembly 50, to an inner surface ofa back cover of the hub of the steering assembly 50, or to an innersurface of the trim extending between the hub portion and the rimportion. In implementations in which the actuator 460 is coupled to theseat or other portion of the vehicle, the actuator 460 is spaced apartfrom the frame or other rigid structural portion of the seat or vehicle.

In some embodiments, the actuator 460 may be disposed between a rimportion of a frame and an outer trim of the rim portion. For example,the actuator 460 may be disposed between an overlay (e.g., overmoldedfoam over the frame) surrounding a frame of the rim portion and theouter trim (e.g., skin) of the rim portion. For example, FIGS. 23-29illustrate an implementation of an actuator assembly 600 for coupling tothe rim portion 52 of the steering wheel assembly 50. The actuatorassembly 600 includes a housing 602 and an actuator 460. The housing 602has an exterior surface 604, an interior surface 606, a radially inneredge 608, a radially outer edge 610, a first circumferential edge 612,and a second circumferential edge 614. The interior 606 and exteriorsurfaces 604 extend between the radially inner 608 and radially outeredges 610 and the first 612 and second circumferential edges 614. Theradially inner edge 608 and the radially outer edge 610 are spaced apartfrom each other and follow the annular shape of the rim portion 52. Theradially inner edge 608 is closer to a center of the steering wheelassembly 50 than the radially outer edge 610. The first circumferentialedge 612 and the second circumferential edge 614 are spaced apart fromeach other, and the edges 612, 614 follow the shape of the outer surfaceof the rim portion 52 as viewed through a plane that bisects the housingand the rim portion 52. The exterior surface 604 is contoured tocorrespond with the contour of the outer surface of the rim portion 52of the steering wheel assembly 50 adjacent the housing 602 prior tocoupling the outer trim (e.g., skin) to the rim portion 52. For example,in an implementation in which the frame 54 of the rim portion 52 isovermolded with foam 59, which is shown by the dotted lines in FIG. 26,and the foam defines the contour of the outer surface of the rim portion52 prior to coupling the outer trim to the rim portion 52, the exteriorsurface 604 of the housing 602 follows the contour of the outer surfaceof the foam such that the housing 602 is not (or is less) visuallyperceptible after the outer trim is coupled to the rim portion 52 andthe housing 602.

The actuator 460 has an output surface 462 and a lower surface 463opposite and spaced apart from the output surface 462. The outputsurface 462 is coupled to the interior surface 606 of the housing 602.For example, the output surface 462 may be coupled to the interiorsurface 606 using an adhesive (e.g., layer or pad), clips, screws, orother suitable fastening mechanism. Audible and/or inaudible pressurewaves are output from the output surface 462 and are received andfurther propagated by the interior surface 606 of the housing 602.

The frame 54 of the rim portion 52 defines a recess 58 adjacent to wherethe actuator assembly 600 is to be coupled to the rim portion 52. Therecess 58 may be overmolded with foam or not, according to variousimplementations. The depth of the recess 58 (with or without foam) issufficiently deep such that the lower surface 463 of the actuator 460 isspaced apart from the frame (or foam) by a gap 620 when the housing iscoupled to the rim portion 52. The gap 620 prevents interference withthe operation of the actuator 460 by the surface below the lower surface463 of the actuator 460. For example, in some implementations, theactuator includes a magnet that moves in a z-direction to cause thepropagation of pressure waves from the output surface 462.

The actuator assembly 600 is coupled to the rim portion 52. For example,the housing 602 may be taped, adhered to, or clipped to the foam surfaceof the rim portion 52. In one implementation, the housing 602 includestabs 622 that extend from the radially inner edge 608 and the radiallyouter edge 610. Each tab 622 has an engagement surface that extends andis biased radially inwardly. The engagement surface may be a protrusion,such as dimple or a ledge. The foam defines openings (not shown) intowhich the tabs 622 extend to prevent movement of the housing 602relative to the rim portion 52 and to maintain the gap 620 between thelower surface 463 of the actuator 460 and the recess 58. In someimplementations, a resilient material (e.g., rubber or elastomericmaterial) is disposed between the housing and the foam, and theresilient material may be selected to provide a range of mechanicalresponses, depending on the input received (i.e., the resilient materialmay either attenuate or amplify the sensation to the operator of thevibration from the pressure waves output by the actuator 460).

According to some implementations, the housing 602 is a stiff material,such as plastic, glass filled nylon, thin metal.

FIG. 29 illustrates one implementation in which four actuator assemblies600 a, 600 b, 600 c, 600 d are coupled to the rim portion 52 at fourcircumferentially spaced apart locations along the rim portion 52.Actuator assemblies 600 a and 600 b are coupled to the rim portion 52above the spoke portion 62A, 62B at 2 and 10 o'clock, respectively, andactuator assemblies 600 c and 600 d are coupled to the rim portion 52below the spoke portion 62A, 62B at 4 and 8 o'clock, respectively. Thefirst circumferential edge 612 a of housing 602 a tapers from the outerradial edge 610 a to the inner radial edge 608 a, and the firstcircumferential edge 612 b of housing 602 b tapers from the outer radialedge 610 b to the inner radial edge 608 b. These tapered edgescorrespond to an area where an operator's thumbs are expected to rest onthe rim portion 52.

In some implementations, the actuator 460 is a speaker. For example, thespeaker may include a standard voice coil assembly with the cone removed(i.e., a coneless voice coil). The system described herein may utilize aplurality of coneless voice coils connected as at least a first speakerand a second speaker. In some implementations, the a respective speakeris a low frequency/high octave speaker. In this regard, a low frequencytactile signal for actuating a haptic exciter (160) may be multiplexedor otherwise combined with a higher frequency audio input to provideadditional degrees of information simultaneously. The higher waveformcould be transposed either in front of the low frequency tactilewaveform, or, after the low frequency tactile waveform, or, in otherembodiments on top of the low frequency tactile waveform used as acarrier signal.

The haptic communication system 2500 described above refers to oneactuator 460, but in various implementations, one or more actuators 460may be used. For example, in some implementations, the actuators 460 arespaced apart from each other within an installation. For example, whencoupled to steering assembly 50, the actuators 460 may be disposedadjacent the left spoke and the right spoke of the steering assembly 50or disposed on a left and a right side of the hub portion (e.g.,adjacent an inner surface of a cover for an air bag module or adjacent aback cover of the hub of the steering assembly 50). The processor 2522is in electrical communication with the actuators 460.

The instructions stored in the memory 2523 cause the processor 2522 toreceive a message from the vehicle communication system 3100, identify avibrational output signal 3112 associated with the message, andcommunicate the vibrational output signal 3112 to the actuator 460. Thevibrational output signal 3112 causes the actuator 460 to propagate aninaudible pressure wave from the output surface of the actuator 460against a surface of the seat 60 or steering assembly 50 in the vehicle,and the pressure wave causes tactilely-perceptible vibration of the seat60 or steering assembly 50, respectively.

In a further or alternative implementation, the instructions cause thesystem processor 2522 to identify an audio output signal 3114 associatedwith the message. The processor 2522 communicates the audio outputsignal 3114 to the actuator 460, and the audio output signal 3114 causesthe actuator 460 to propagate an audible pressure wave. For example, theaudio output signal 3114 may be selected from one or more stored audiooutput signals. The stored audio output signals are accessible to theprocessor 2522 for communicating the identified audio output signal 3114to the actuator 460 such that the audio output signal 3114 causes theactuator 460 to propagate an audible pressure wave from the outputsurface of the actuator 460. For example, the message is a warningmessage 3105A received from a vehicle safety system 3105, and the audiooutput signal 3114 is identified from a plurality of audio outputsignals associated with that warning message.

As another example, the message received by the processor 2522 mayinclude an audio signal, and the audio output signal 3114 identified andcommunicated to the actuator 460 is the audio signal received by theprocessor 2522. For example, the audio signal from a cellular telephonecall being routed through the vehicle communication system 3100 via alocal area network (e.g., a Bluetooth network) may be output through theactuator 460.

In implementations in which the instructions cause the processor 2522 tooutput vibrational 3112 and audio output signals 3114 sequentially fromthe actuator 460 based on the message received, the audio output signal3114 may be communicated before the vibrational output signal 3112, orvice versa. And, the processor 2522 may delay the communication of eachsignal 3112, 3114 by a predetermined time period. For example, in oneimplementation, the delay may be 25 milliseconds or less. In otherimplementations, the delay can be selected based on the haptic effectdesired for the user.

In certain implementations, two or more actuators 460 are disposed onthe steering assembly 50 or in the seat 60 and are spaced apart fromeach other. The processor 2522 is in electrical communication with theactuators 460. Instructions stored on the memory 2523 cause theprocessor 2522 to identify a first audio output signal associated withthe message received by the processor 2522 from another system (e.g.,the vehicle communication system 3100, the vehicle safety system 3105,and/or the vehicle operation system 3106), and communicate the firstaudio output signal to the first actuator 460. The first audio outputsignal causes the first actuator 460 to propagate a first audiblepressure wave. The instructions also cause the processor to identify asecond audio output signal associated with the message received by theprocessor 2522 from the other system and communicate the second audiooutput signal to the second actuator 460. The second audio output signalcauses the second actuator 460 to propagate a second audible pressurewave. The first audible pressure wave and the second audible pressurewave may provide a stereo sound effect, or the first and second audiooutput signals may be communicated sequentially and with a time delay.For example, the audio output signals may be communicated in aparticular pattern.

In a further or additional implementation, the instructions cause theprocessor 2522 to identify a first vibrational output signal and asecond vibrational output signal associated with the received messageand communicate the first vibrational output signal to the firstactuator 460 and the second vibrational message to the second actuator460. The first and second vibrational output signals cause the first andsecond actuators 460, respectively, to propagate inaudible pressurewaves at or near the resonant frequency of the steering assembly 50.Similar to the effect described above in regard to the switch assembly100, the inaudible pressure waves cause tactilely-perceptible vibrationof the steering assembly 50.

According to various implementations, the first and second audio outputsignals may be output simultaneously or sequentially. In addition, thefirst and second vibrational output signals may be output simultaneouslyor sequentially. Furthermore, the first audio signal, the second audiosignal, the first vibrational signal, and the second vibrational signalmay be output sequentially in any order. Additionally, the abovedescribed amplifier 530 may be controlled by the processor to eitherattenuate or amplify audio and haptic outputs from a series of speakers.For example, the instructions from the processor 2522 direct thecommunication of the first and second vibrational output signalssequentially, such that the first vibrational output signal iscommunicated prior to the second vibrational output signal, or viceversa. Similarly, the programmed instructions may cause the processor2522 to output the communication of the first and second audio outputsignals sequentially, such that the first audio output signal iscommunicated prior to the second audio output signal, or vice versa. Inimplementations in which the output includes audio and vibrationaloutput, the audio output may be communicated prior to the vibrationaloutput, or vice versa. And, the processor 2522 may delay thecommunication of one or both audio signals or one or both vibrationalsignals by a predetermined time period. For example, in oneimplementation, the delay may be 25 milliseconds or less. In otherimplementations, the delay can be selected based on the haptic effectdesired for the user. The time delay may be associated with the messagereceived by the processor from the other system.

In some implementations, the switch assembly 100 and the hapticcommunication system 2500 are configured to receive input data fromother systems via wired and wireless electronic communications. Forexample, the switch assembly 100 and the haptic communication system2500 include respective sets of computerized instructions accessible byrespective processors, and these instructions facilitate data flowbetween haptic systems and other systems across a communication network.

In addition, in various implementations, the identification of audioand/or vibrational output signals to communicate, the order in whichthey are communicated, and/or the delay between propagation of discretepressure waves by the actuator can define a haptic pattern. The hapticpattern may be selected from a plurality of stored haptic patterns basedon the message received by the processor, such as processors 522, 2522.

The drawings illustrate the switch assembly as viewed in an uprightorientation in which the central longitudinal axis A-A is verticallyoriented. However, the orientation shown in the drawings should notlimit how the switch assembly may be oriented within the vehicle. Forexample, in various implementations, the switch assembly is disposed inthe vehicle such that the central longitudinal axis A-A is horizontal orhas a horizontal component relative to the ground.

The terminology used herein is for the purpose of describing particularimplementations only and is not intended to be limiting of theinvention. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theimplementation was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious implementations with various modifications as are suited to theparticular use contemplated.

1. A haptic communication system comprising: an actuator having anoutput surface, the output surface being coupled to a seat or a steeringassembly of a vehicle; and a processor in electrical communication withthe actuator, a memory, and a vehicle communication system that isseparate from the haptic communication system, the memory storinginstructions for execution by the processor, wherein the instructionscause the processor to: receive a message from the vehicle communicationsystem; identify a vibrational output signal associated with themessage; and communicate the vibrational output signal to the actuator,the vibrational output signal causing the actuator to propagate aninaudible pressure wave from the output surface against a surface of theseat or steering assembly, respectively, and the pressure wave causingtactilely-perceptible vibration of the seat or steering assembly,respectively. 2.-3. (canceled)
 4. The haptic communication system ofclaim 1, wherein the actuator is disposed between a rim portion of aframe and an outer trim of the steering assembly.
 5. The hapticcommunication system of claim 1, wherein the actuator is coupled to aninner surface of an outer cover of steering wheel assembly.
 6. Thehaptic communication system of claim 1, wherein the actuator is aspeaker, and the instructions further cause the processor to identify anaudio output signal from one or more stored audio output signals andcommunicate the audio output signal to the speaker, the audio outputsignal causing the speaker to propagate an audible pressure wave fromthe output surface of the speaker.
 7. The haptic communication system ofclaim 6, wherein the instructions further cause the processor tocommunicate the audio output signal and the vibrational output signal insequence. 8.-10. (canceled)
 11. The haptic communication system of claim1, wherein the actuator is a first actuator and the haptic communicationsystem comprises a second actuator coupled to the seat or steeringassembly, the second actuator being spaced apart from the firstactuator.
 12. The haptic communication system of claim 11, wherein theprocessor is in electrical communication with the second actuator, thevibrational output signal is a first vibrational output signal, and theinstructions further cause the processor to identify a secondvibrational output signal associated with the message and communicatethe second vibrational output signal to the second actuator, the secondvibrational output signal causing the actuator to propagate a secondinaudible pressure wave from a respective output surface of the secondactuator against a different surface of the seat or steering assembly,respectively, to which the second actuator is coupled, the secondinaudible pressure wave causing additional tactilely-perceptiblevibration of the seat or steering assembly, respectively.
 13. (canceled)14. The haptic communication system of claim 12 wherein thecommunication of the first and second vibrational output signals issequential. 15.-17. (canceled)
 18. A haptic communication systemcomprising: a coneless voice coil coupled to a steering assembly; and aprocessor in electrical communication with the coneless voice coil, amemory, and a vehicle communication system that is separate from thehaptic communication system, the memory storing instructions forexecution by the processor, wherein the instructions cause the processorto: receive a message from the vehicle communication system; in responseto receiving the message, identify an audio output signal associatedwith the message; and communicate the audio output signal to theconeless voice coil, the audio output signal causing the coneless voicecoil to propagate an audible pressure wave. 19.-32. (canceled)
 33. Thehaptic communication system of claim 18, wherein the instructionsfurther cause the processor to identify a vibrational output signalassociated with the message and communicate the vibrational outputsignal to the coneless voice coil, the vibrational output signal causingthe coneless voice coil, to propagate an inaudible pressure wave that isclose to or at the resonant frequency of the steering assembly, theinaudible pressure wave causing tactilely-perceptible vibration of thesteering assembly. 34.-35. (canceled)
 36. The haptic communicationsystem of claim 18, wherein the coneless voice coil is disposed within aswitch assembly, the switch assembly being coupled to the steeringassembly.
 37. The haptic communication system of claim 18, wherein theconeless voice coil is coupled to the steering assembly between a spokeportion of a frame and an outer trim of the steering assembly and isspaced apart from the frame.
 38. (canceled)
 39. The haptic communicationsystem of claim 18, wherein the coneless voice coil is coupled to aninner surface of a cover of an air bag module, the air bag module beingcoupled to a hub portion of a frame of the steering assembly. 40.-43.(canceled)
 44. The haptic communication system of claim 18, wherein theconeless voice coil is coupled to a back cover of a hub of the steeringassembly.
 45. A switch assembly coupled to a steering assembly, thesteering assembly having a resonant frequency, comprising: a touch platehaving a touch surface and an inner surface, the inner surface beingopposite and spaced apart from the touch surface; at least one forcesensor disposed adjacent the inner surface of the touch plate, the atleast one force sensor for receiving a force applied to the touchsurface; an actuator having an output surface from which pressure wavesare propagated along an axis of propagation (A-A), the output surface ofthe actuator being vibrationally coupled to the inner surface of thetouch plate; a processor electrically coupled to a memory, the at leastone force sensor, the actuator, and a vehicle communication system, thevehicle communication system being separate from the switch assembly,the memory storing instructions for execution by the processor, whereinthe instructions cause the processor to: receive a force signal from theat least one force sensor, identify whether a touch event occurred basedon the force signal, in response to identifying the touch event,communicate a first output signal to the actuator, the first outputsignal causing the actuator to propagate a first inaudible pressure wavehaving a frequency (f_(I)) within a switch feedback frequency range, theswitch feedback frequency range being below the resonant frequency(f_(R)) of the steering assembly, the first pressure wave causing afirst tactilely-perceptible vibration of the touch plate along the axisof propagation (A-A), wherein the vibration caused by the first pressurewave of the first output signal is isolated to the switch assembly.46.-53. (canceled)
 54. The switch assembly of claim 45, wherein theinstructions further cause the processor to: receive an ambientvibration signal associated with ambient vibration of the steeringassembly; identify a pressure wave offset (ΔV) associated with theambient vibration; and modify the second output signal based on theidentified pressure wave offset (ΔV) to change a characteristic of thesecond pressure wave.
 55. The switch assembly of claim 54, wherein theat least one force sensor comprises a plurality of force sensors, andthe ambient vibration signal is determined by the processor based on anaverage magnitude and frequency of each of the force signals generatedby the force sensors.
 56. The switch assembly of claim 55, wherein theinstructions further cause the processor to determine whether theaverage magnitude exceeds a threshold, and the processor identifies thepressure wave offset in response to determining that the averagemagnitude exceeds the threshold.
 57. The switch assembly of claim 56,wherein the instructions further cause the processor to: receive avehicle speed; identify a pressure wave offset (ΔV) associated with thevehicle speed; modify the second output signal based on the identifiedpressure wave offset (ΔV) to change a characteristic of the secondinaudible pressure wave.
 58. (canceled)
 59. The switch assembly of claim54, wherein the pressure wave offset comprises a frequency offset, anamplitude offset, and/or a duration offset. 60.-63. (canceled)